Bus bar locating feature and method

ABSTRACT

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a terminal holder, a terminal at least partially surrounded by the terminal holder, and a bus bar module connectable to the terminal holder. One of the terminal holder and the bus bar module includes at least one locating feature to position the bus bar module in a welding position relative to the terminal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 14/059,481,which was filed on Oct. 22, 2013 and is now U.S. Pat. No. 9,478,788.

TECHNICAL FIELD

This disclosure relates to an electrified vehicle, and moreparticularly, but not exclusively, to electrically connecting bus barsto terminals of a battery assembly of the electrified vehicle.

BACKGROUND

Hybrid electric vehicles (HEV's), plug-in hybrid electric vehicles(PHEV's), battery electric vehicles (BEV's), fuel cell vehicles andother known electrified vehicles differ from conventional motor vehiclesin that are powered by one or more electric machines (i.e., electricmotors and/or generators) instead of or in addition to an internalcombustion engine. High voltage current is typically supplied by one ormore battery assemblies that store electrical power for powering theelectric machine(s).

Electrified vehicle battery assemblies include one or more battery cellsthat are configured in a series or series-parallel string in order toobtain the voltage and power levels that are necessary to drive theelectrified vehicle. The battery cells must be reliably connected to oneanother in order to achieve these voltage and power levels. Bus bars maybe used to electrically connect the battery cells of a battery assembly.The bus bars are commonly located and secured to the terminals of thebattery cells via a bolted joint.

SUMMARY

A battery assembly according to an exemplary aspect of the presentdisclosure includes, among other things, a terminal holder, a terminalat least partially surrounded by the terminal holder, and a bus barmodule connectable to the terminal holder. One of the terminal holderand the bus bar module includes at least one locating feature toposition the bus bar module in a welding position relative to theterminal.

In a further non-limiting embodiment of the foregoing battery assembly,the at least one locating feature includes a pin structure.

In a further non-limiting embodiment of either of the foregoing batteryassemblies, the pin structure is received within an opening of the otherof the terminal holder and the bus bar module.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the at least one locating feature extends from the terminalholder.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the at least one locating feature extends from the bus barmodule.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the at least one locating feature includes a plurality ofclips configured to snap into openings of the other of the terminalholder and the bus bar module.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the bus bar module includes a housing and a bus bar.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, at least one tab is configured to retain the bus barrelative to the housing.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the terminal includes a landing that contacts the bus barmodule and a base in contact with the terminal holder.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the landing extends along a first plane and the base extendsalong a second plane that is spaced from the first plane.

A battery assembly according to an exemplary aspect of the presentdisclosure includes, among other things, a terminal holder and a bus barmodule configured to attach to the terminal holder. One of the terminalholder and the bus bar module includes a locating feature and the otherof the terminal holder and the bus bar module includes an openingconfigured to receive the locating feature.

In a further non-limiting embodiment of the foregoing battery assembly,a terminal extends at least partially between the terminal holder andthe bus bar module.

In a further non-limiting embodiment of either of the foregoing batteryassemblies, the terminal includes a landing that extends along a firstplane and a base that extends along a second plane that is spaced fromthe first plane.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the locating feature includes a pin structure that extendsfrom the terminal holder.

In a further non-limiting embodiment of any of the foregoing batteryassemblies, the locating feature includes a clip that extends from thebus bar module.

A method according to another exemplary aspect of the present disclosureincludes, among other things, locating a bus bar module relative to aterminal of a battery assembly, connecting the bus bar module to aterminal holder and welding the bus bar module to the terminal after theconnecting step.

In a further non-limiting embodiment of the foregoing method, the stepof locating includes inserting a pin structure of one of the terminalholder and the bus bar module into an opening in the other of theterminal holder and the bus bar module.

In a further non-limiting embodiment of either of the foregoing methods,the step of locating includes inserting a clip of one of the terminalholder and the bus bar module into an opening in the other of theterminal holder and the bus bar module.

In a further non-limiting embodiment of any of the foregoing methods,the step of connecting includes snapping the bus bar module onto theterminal holder.

In a further non-limiting embodiment of any of the foregoing methods,the step of welding includes positioning a weld tool relative to awindow of the bus bar module and using the weld tool to weld a bus barof the bus bar module to the terminal.

The embodiments, examples and alternatives of the preceding paragraphs,the claims, or the following description and drawings, including any oftheir various aspects or respective individual features, may be takenindependently or in any combination. Features described in connectionwith one embodiment are applicable to all embodiments, unless suchfeatures are incompatible.

The various features and advantages of this disclosure will becomeapparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates a powertrain of an electrified vehicle.

FIG. 2 illustrates a battery assembly that can be incorporated into anelectrified vehicle.

FIG. 3 illustrates an exemplary terminal of a battery cell.

FIG. 4 illustrates an exemplary bus bar module.

FIG. 5 illustrates a method for electrically connecting battery cells ofa battery assembly with a bus bar module.

FIG. 6 illustrates a locating feature for locating a bus bar modulerelative to a battery terminal.

FIG. 7 illustrates another exemplary battery assembly.

DETAILED DESCRIPTION

This disclosure relates to a locating feature and method for locating abus bar module relative to a terminal of a battery cell of anelectrified vehicle battery assembly. The locating feature may beincorporated into either a bus bar module or a terminal holder and isconfigured to both laterally and vertically locate the bus bar module ata proper position relative to the terminal. Once located, a bus bar ofthe bus bar module can be welded to the terminal to electrically connectthe battery cells of the battery assembly. These and other features arediscussed in greater detail herein.

FIG. 1 schematically illustrates a powertrain 10 for an electrifiedvehicle 12, such as a HEV. Although depicted as a HEV, it should beunderstood that the concepts described herein are not limited to HEV'sand could extend to other electrified vehicles, including but notlimited to, PHEV's, BEV's, and fuel cell vehicles.

In one embodiment, the powertrain 10 is a powersplit system that employsa first drive system that includes a combination of an engine 14 and agenerator 16 (i.e., a first electric machine) and a second drive systemthat includes at least a motor 36 (i.e., a second electric machine), thegenerator 16 and a battery assembly 50. For example, the motor 36, thegenerator 16 and the battery assembly 50 may make up an electric drivesystem 25 of the powertrain 10. The first and second drive systemsgenerate torque to drive one or more sets of vehicle drive wheels 30 ofthe electrified vehicle 12, as discussed in greater detail below.

The engine 14, such as an internal combustion engine, and the generator16 may be connected through a power transfer unit 18. In onenon-limiting embodiment, the power transfer unit 18 is a planetary gearset. Of course, other types of power transfer units, including othergear sets and transmissions, may be used to connect the engine 14 to thegenerator 16. The power transfer unit 18 may include a ring gear 20, asun gear 22 and a carrier assembly 24. The generator 16 is driven by thepower transfer unit 18 when acting as a generator to convert kineticenergy to electrical energy. The generator 16 can alternatively functionas a motor to convert electrical energy into kinetic energy, therebyoutputting torque to a shaft 26 connected to the carrier assembly 24 ofthe power transfer unit 18. Because the generator 16 is operativelyconnected to the engine 14, the speed of the engine 14 can be controlledby the generator 16.

The ring gear 20 of the power transfer unit 18 may be connected to ashaft 28 that is connected to vehicle drive wheels 30 through a secondpower transfer unit 32. The second power transfer unit 32 may include agear set having a plurality of gears 34A, 34B, 34C, 34D, 34E, and 34F.Other power transfer units may also be suitable. The gears 34A-34Ftransfer torque from the engine 14 to a differential 38 to providetraction to the vehicle drive wheels 30. The differential 38 may includea plurality of gears that enable the transfer of torque to the vehicledrive wheels 30. The second power transfer unit 32 is mechanicallycoupled to an axle 40 through the differential 38 to distribute torqueto the vehicle drive wheels 30.

The motor 36 can also be employed to drive the vehicle drive wheels 30by outputting torque to a shaft 46 that is also connected to the secondpower transfer unit 32. In one embodiment, the motor 36 and thegenerator 16 are part of a regenerative braking system in which both themotor 36 and the generator 16 can be employed as motors to outputtorque. For example, the motor 36 and the generator 16 can each outputelectrical power to a high voltage bus 48 and the battery assembly 50.The battery assembly 50 may be a high voltage battery that is capable ofoutputting electrical power to operate the motor 36 and the generator16. Other types of energy storage devices and/or output devices can alsobe incorporated for use with the electrified vehicle 12.

The motor 36, the generator 16, the power transfer unit 18, and thepower transfer unit 32 may generally be referred to as a transaxle 42,or transmission, of the electrified vehicle 12. Thus, when a driverselects a particular shift position, the transaxle 42 is appropriatelycontrolled to provide the corresponding gear for advancing theelectrified vehicle 12 by providing traction to the vehicle drive wheels30.

The powertrain 10 may additionally include a control system 44 formonitoring and/or controlling various aspects of the electrified vehicle12. For example, the control system 44 may communicate with the electricdrive system 25, the power transfer units 18, 32 or other components tomonitor and/or control the electrified vehicle 12. The control system 44includes electronics and/or software to perform the necessary controlfunctions for operating the electrified vehicle 12. In one embodiment,the control system 44 is a combination vehicle system controller andpowertrain control module (VSC/PCM). Although it is shown as a singlehardware device, the control system 44 may include multiple controllersin the form of multiple hardware devices, or multiple softwarecontrollers within one or more hardware devices.

A controller area network (CAN) 52 allows the control system 44 tocommunicate with the transaxle 42. For example, the control system 44may receive signals from the transaxle 42 to indicate whether atransition between shift positions is occurring. The control system 44may also communicate with a battery control module of the batteryassembly 50, or other control devices.

Additionally, the electric drive system 25 may include one or morecontrollers 54, such as an inverter system controller (ISC). Thecontroller 54 is configured to control specific components within thetransaxle 42, such as the generator 16 and/or the motor 36, such as forsupporting bidirectional power flow. In one embodiment, the controller54 is an inverter system controller combined with a variable voltageconverter (ISC/VVC).

The battery assembly 50 is an exemplary energy storage device for usewith the electrified vehicle 12. The battery assembly 50 may be a highvoltage battery that is capable of outputting electrical power tooperate the motor 36 and/or the generator 16. Other types of energystorage devices and/or outputting devices can also be used with theelectrified vehicle 12. The battery assembly 50 may include one or morebattery cells 60 (shown schematically in FIG. 1), such as lithium-ionbattery cells. The battery cells 60 must be electrically coupled to oneanother in order to drive the motor 36 and/or generator 16. Exemplarybus bar modules for electrically connecting the battery cells 60 aredescribed in greater detail below.

FIG. 2 illustrates an exemplary battery assembly 50 that may include twoor more battery cells 60 that store power for driving the electricmachines 16, 36 of the electrified vehicle 12 (see FIG. 1). In thisembodiment, the battery assembly 50 is shown with two battery cells.However, the battery assembly 50 could include any number of batterycells 60 within the scope of this disclosure. The number of batterycells 60 could depend on the energy requirements of the loads beingpowered by the battery assembly 50, among other design criteria.

Each battery cell 60 may include two terminals 64 that extend from asurface 69 of the battery cell 60. A terminal holder 65 generallysurrounds each terminal 64. In one non-limiting embodiment, one terminalholder 65 extends about a perimeter of each terminal 64. The terminalholders 65 are attached to the surface 69 and may support, protect,and/or isolate the terminals 64.

A bus bar module 62 may be employed to electrically connect the batterycells 60 of the battery assembly 50. In one embodiment, the bus barmodule 62 connects to one or more terminal holders 65 to locate andsecure the bus bar module 62 relative to the terminals 64 of the batterycells 60.

In one non-limiting embodiment, the terminals 64 are made of a metallicconductive material and the bus bar module 62 and terminal holders 65include a polymeric material. Other materials may also be used withinthe scope of this disclosure.

FIG. 3 illustrates an exemplary terminal 64 that can be incorporatedinto a battery cell 60 of the battery assembly 50. In this embodiment,the terminal 64 includes a “diving board” shape. For example, theexemplary terminal 64 may include a landing 66 and a base 68. Aconnector 70 joins the landing 66 to the base 68. In one embodiment, theconnector 70 is slightly curved to join the landing 66 to the base 68.The landing 66 of the terminal 64 may be secured to the bus bar module62 and may hover above the terminal holder 65, whereas the base 68 ofthe terminal 64 may be secured directly to the terminal holder 65 (seeleft hand side of FIG. 2).

In one non-limiting embodiment, the landing 66 extends along a firstplane P1 and the base 68 extends along a second plane P2. The firstplane P1 may be spaced by a distance D from the second plane P2. Inother words, the landing 66 may be slightly elevated relative to thebase 68.

FIG. 4 illustrates an exemplary bus bar module 62 that may be employedto electrically connect adjacent battery cells 60 of a battery assembly50 (see FIG. 2). The bus bar module 62 may include a bus bar 72 and ahousing 74. The bus bar 72 may be made of a metallic, conductivematerial similar (or dissimilar) to that of the terminals 64 (see FIG.3), whereas the housing 74 may be constructed of a polymeric material.

In one embodiment, the bus bar 72 is held against an inner surface 76 ofthe housing 74 by one or more tabs 78. The tabs 78 may protrude fromsidewalls 79 of the housing 74 and extend in a direction toward anopposite sidewall 79. Any number and configuration of tabs may beprovided to retain the bus bar 72 relative to the housing 74.

The bus bar module 62 may additionally include one or more locatingfeatures 80 for locating the bus bar module 62 in a welding positionrelative to a terminal. For example, it may be desirable to locate thebus bar module 62 in a position appropriate for welding the bus bar 72to terminals 64 to electrically connect battery cells 60 of a batteryassembly 50 (see FIG. 2).

In one non-limiting embodiment, the bus bar module 62 includes aplurality of locating features 80 that extend inwardly from a bottomsurface 81 of the sidewalls 79 of the housing 74. Any number of locatingfeatures 80 could be designed as part of the housing 74. The locatingfeatures 80 may be tabs, clips or other features that are configured tosnap or connect to corresponding openings 82 formed in the terminalholders 65 (see FIG. 2). Of course, an opposite configuration iscontemplated in which the locating features are formed as part of theterminal holders 65 and the openings are formed in the bus bar module 62(see, for example, FIG. 7).

In one non-limiting embodiment, the locating features 80 include ledges85. The ledges 85 may be received through openings 82 of the terminalholder 65 and may then abut a surface of the terminal holder 65 (seeFIGS. 2 and 5) to provide a snap fit connection between the bus barmodule 62 and the terminal holder 65.

At least one sidewall (here, the sidewall 79-A) of the housing 74 mayexclude any locating features 80. Once connected and in the weldingposition, the sidewall 79-A of the bus bar module 62 is located abovethe terminal(s) 64 and therefore does not require any feature for matingwith the terminal holder 65 (see FIG. 2).

The housing 74 of the bus bar module 62 may additionally include one ormore windows 84. As discussed in greater detail below, the windows 84can accommodate a weld tool for welding the bus bar 72 to theterminal(s) 64 once the bus bar module 62 is properly located andpositioned in a welding position.

FIG. 5, with continued reference to FIGS. 1-4, schematically illustratesa method for electrically connecting battery cells 60 of a batteryassembly 50 with a bus bar module 62. A bus bar module 62 is firstlocated in a welding position relative to a terminal 64 of a batterycell 60 via the locating features 80. For example, the locating features80 of the housing 74 of the bus bar module 62 may be aligned andpositioned directly over the openings 82 of the terminal holder 65.

Next, once the locating features 80 are positioned relative to theopenings 82, the bus bar module 62 may be secured relative to theterminal holder 65. In one non-limiting embodiment, the locatingfeatures 80 are configured as clips and the bus bar module 62 is snapfit onto the terminal holder 65. Once connected, the ledges 85 of thelocating features 80 may abut against a surface 87 that surrounds theopenings 82 of the terminal holder 65 to retain the bus bar module 62 tothe terminal holder 65 (see FIG. 6). The bus bar module 62 is secured ina welding position once connected to the terminal holder 65 and isproperly located in each of an X direction (a first lateral direction),a Y direction (a second lateral direction) and a Z direction (a verticaldirection) by the locating features 80. In other words, the locatingfeatures 80 both laterally and vertically locate the bus bar module 62at a proper position relative to the terminal(s) 64.

Once positioned in the welding position, the bus bar 72 of the bus barmodule 62 may be welded to one or more terminals 64. In one embodiment,a weld tool 86 is positioned relative to the windows 84 of the housing74 of the bus bar module 62 and may be used to weld the bus bar 72directly to the landing 66 of the terminal 64 at welds W. The landing 66may be flat or planar in order to facilitate receiving the welds W. Theexemplary welds W may be laser welded lap joints, ultrasonic welds,resistance welds, etc. The welding process fuses the bus bar 72 to aportion of the terminal 64 in order to electrically connect adjacentbattery cells 60. Several separate welds W may be used to secure the busbar 72 to the terminal 64.

Another exemplary battery assembly 150 is illustrated in FIG. 7. In thisdisclosure, like reference numbers designate like elements whereappropriate and reference numerals with the addition of 100 or multiplesthereof designate modified elements that are understood to incorporatethe same features and benefits of the corresponding original elements.

In this alternative embodiment, a locating feature 180 extends from aterminal holder 165 rather than a bus bar module 162 of the batteryassembly 150. The locating feature 180 may be received by an opening 182formed in the bus bar module 162 to secure the bus bar module 162 to theterminal holder 165. In one non-limiting embodiment, the locatingfeature 180 includes a pin structure 190. The pin structure 190 can havea round cross-section, a rectangular cross-section, a taperingcross-section, etc. The pin structure 190 limits lateral movement of thebus bar module 162 relative to a terminal 164 of the battery cell 160.Once the pin structure 190 is received by the opening 182, a landing 166of the terminal 164 can be welded to the bus bar 72 of the bus barmodule 162 in a manner similar to that shown in FIG. 5.

Although the different non-limiting embodiments are illustrated ashaving specific components or steps, the embodiments of this disclosureare not limited to those particular combinations. It is possible to usesome of the components or features from any of the non-limitingembodiments in combination with features or components from any of theother non-limiting embodiments.

It should be understood that like reference numerals identifycorresponding or similar elements throughout the several drawings. Itshould be understood that although a particular component arrangement isdisclosed and illustrated in these exemplary embodiments, otherarrangements could also benefit from the teachings of this disclosure.

The foregoing description shall be interpreted as illustrative and notin any limiting sense. A worker of ordinary skill in the art wouldunderstand that certain modifications could come within the scope ofthis disclosure. For these reasons, the following claims should bestudied to determine the true scope and content of this disclosure.

What is claimed is:
 1. A battery assembly, comprising: a battery cell; aterminal of said battery cell including a base, a landing, and a curvedconnector joining said base to said landing; a terminal holder receivingsaid terminal; a bus bar module configured to attach to said terminalholder; and one of said terminal holder or said bus bar module includesa locating feature and the other of said terminal holder or said bus barmodule includes an opening configured to receive said locating feature.2. The battery assembly as recited in claim 1, wherein said terminalextends at least partially between said terminal holder and said bus barmodule.
 3. The battery assembly as recited in claim 1, wherein saidlanding extends along a first plane and said base extends along a secondplane that is spaced from said first plane.
 4. The battery assembly asrecited in claim 1, wherein said locating feature includes a pinstructure that extends from said terminal holder.
 5. The batteryassembly as recited in claim 1, wherein said locating feature includes aclip that extends from said bus bar module.
 6. The battery assembly asrecited in claim 1, wherein said terminal is diving board shaped.
 7. Thebattery assembly as recited in claim 1, wherein said bus bar moduleincludes a housing and a bus bar retained to said housing.
 8. Thebattery assembly as recited in claim 7, wherein said housing is made ofa polymeric material and said bus bar is made of a metallic material. 9.The battery assembly as recited in claim 7, wherein said housingincludes a plurality of windows sized to expose said bus bar to a weldtool.
 10. The battery assembly as recited in claim 1, wherein saidlocating feature is adapted to position said bus bar module in a weldingposition relative to said terminal.
 11. The battery assembly as recitedin claim 1, wherein said base is secured directly to said terminalholder and said landing hovers above said terminal holder at a locationoutside of said battery cell.
 12. The battery assembly as recited inclaim 1, comprising a weld joint that secures said landing of saidterminal to a bus bar of said bus bar module.
 13. The battery assemblyas recited in claim 1, wherein said bus bar module includes a polymerichousing and a metallic bus bar retained against an inner surface of saidpolymeric housing by a tab that protrudes from said polymeric housing.14. A battery assembly, comprising: a battery cell including a terminalmounted to an external surface of said battery cell and a terminalholder circumscribing said terminal and mounted to said externalsurface; a bus bar module snap fit onto said terminal holder andincluding a housing and a bus bar retained to said housing; and a windowof said housing exposing a portion of said bus bar, wherein saidterminal includes a base secured directly to said terminal holder, alanding that hovers above said terminal holder, and a curved connectorjoining said base to said landing.
 15. The battery assembly as recitedin claim 14, wherein one of said terminal holder and said bus bar moduleincludes a locating feature and the other of said terminal holder andsaid bus bar module includes an opening configured to receive saidlocating feature.
 16. The battery assembly as recited in claim 15,wherein said locating feature is adapted to position said bus bar modulein a welding position relative to said terminal.
 17. The batteryassembly as recited in claim 14, wherein said window exposes said busbar to a weld tool.
 18. The battery assembly as recited in claim 14,wherein said terminal extends along a first axis that is parallel to alongitudinal axis of said battery cell, and said bus bar module extendsalong a second axis that is transverse to said first axis and saidlongitudinal axis.